Heat exchanger for a motor vehicle comprising flexible fluid lines and holding structure

ABSTRACT

A heat exchanger for a motor vehicle includes first fluid lines of a flexible material, through which a first fluid (F1) flows, and a holding structure with holding elements. The first fluid lines and the holding elements form a woven structure. The holding elements are in a thread-like manner and extend along a second direction of extension (R2), at right angles to a first direction of extension (R1). The heat exchanger, through which a second fluid (F2) flows, is separated from the first fluid (F1). The woven structure includes a first and second partial woven structures and are formed separately. The first partial woven structure and the second partial structure are arranged so that the second fluid (F2) flows through the woven structure space, formed between the two partial woven structures. The first and the second partial woven structures are at an angle relative to one another.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to International Patent Application No.: PCT/EP2016/079135 filed on Nov. 29, 2016, which claims priority to German Patent Application No.: DE 10 2015 224 605.1 filed on Dec. 8, 2015, the contents of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The invention relates to a heat exchanger, particularly for a motor vehicle.

BACKGROUND

Heat exchangers are used in vehicle construction in many ways, for instance to cool charge air of an internal combustion engine, which is charged by means of a turbocharger. The charge air to be cooled is thereby guided through the heat exchanger, through which, in turn, a coolant flows so as to be media-separated from the charge air. Heat is extracted from the charge air to be cooled within the heat exchanger by means of heat exchange and is transferred to the coolant. The coolant is typically circulated in a cooling circuit, into which the coolant lines of the heat exchanger are integrated. So-called rib-tube heat exchangers, which are used as direct charge air cooler to cool charge air, which is charged by means of a charging device, for example an exhaust gas turbocharger, are known from the prior art.

It is the object of the present invention to show new ways for the development of heat exchangers.

SUMMARY

This object is solved by means of the subject matter of the independent patent claims. Preferred embodiments are the subject matter of the dependent patent claims.

It is thus the general idea of the invention to provide a heat exchanger comprising a plurality of fluid lines, through which a first fluid can flow, of a flexible material, and to mechanically stabilize these flexible fluid lines by means of a holding structure. The holding structure thereby comprises a plurality of holding elements. According to the invention, the fluid lines form a woven structure with the holding elements of the holding structure. For this purpose, the fluid lines and the holding elements are embodied and are arranged relative to one another in such a way that the fluid lines form the weft threads and the holding elements form the warp threads of the woven structure or vice versa. Compared to common fluid lines of a stiff material, the embodiment of the fluid lines of a flexible material allows for a flexible arrangement of the fluid lines. A minimum of stiffness, which is required for the practical use of the heat exchanger, particularly in a motor vehicle, can thereby be attained by means of the holding elements of the holding structure. Said holding elements thereby do not only serve for the mechanical stabilization of the fluid lines, but also as additional heat exchange surfaces, when a second fluid, which is to perform a heat exchange with the first fluid, which flows through the first fluid lines, flows around the first fluid lines—fluidically separated from the first fluid.

A heat exchanger according to the invention comprises a plurality of first fluid lines of a flexible material, through which a first fluid can flow. The heat exchanger also comprises a holding structure, which comprises a plurality of holding elements for holding the first fluid lines. According to the invention, the first fluid lines and the holding elements form at least one woven structure. The first fluid lines thereby form the warp threads and the holding elements form the weft threads of the woven structure, or vice versa. The first fluid may thereby for instance be a coolant, which serves to cool a second fluid, particularly air, which flows through the first fluid lines on the outside—fluidically separated from the first fluid—and which is in thermal contact with the first fluid via the line walls of the first fluid lines.

In a preferred embodiment, the first fluid lines are embodied as flexible tubular bodies, which in each case define a line interior in a fluid-tight manner, through which the first fluid can flow. Heat exchanger arrangements comprising a variable geometry can be realized in this way. In particular a curved embodiment of the tubular bodies is conceivable. For this purpose, the holding elements can also comprise a flexible material or can consist of a flexible material.

In a further preferred embodiment, second fluid lines, through which the second fluid can flow, are embodied by spaces formed between the first fluid lines. The embodiment of said spaces is realized in such a way that the first fluid is fluidically separated from the second fluid by means of the flexible material of the first fluid lines and can be thermally coupled or is thermally coupled, respectively, thereto. A particularly effective heat exchange can be realized in this way between the first and the second fluid. This measure is associated with a particularly high efficiency of the heat exchanger.

The holding elements of the holding structure are advantageously embodied in a thread-like manner and extend along a second direction of extension. The second direction of extension runs at right angles to a first direction of extension, along which the first fluid lines extend. The heat exchanger, through which a second fluid can flow, is embodied fluidically separated from the first fluid and along the second direction of extension in this alternative. An unwanted reduction of the fluid pressure of the second fluid when flowing through the heat exchanger can be largely prevented in this way, in the ideal case even completely, by means of the holding structure.

In an advantageous further development, at least one holding element is embodied as flexible support wire. Particularly preferably, this applies for all of the support wires, which are present in the heat exchanger. This measure allows for a technically simple realization of the holding elements, which is associated with significant cost advantages in response to the production of the heat exchanger.

In a further preferred embodiment, at least two first fluid lines are arranged at a distance from one another along the second direction of extension. The distribution of the first fluid to at least two fluid lines associated with this measure allows for an increase of the heat-transferring surface between the first fluid, which flows through the first fluid lines on the inside, and the second fluid, which flows around the at least two first fluid lines on the outside.

In a further preferred embodiment, provision is made for at least two woven structures of first fluid lines and holding elements, which are in each case arranged in a woven structure plane, which is in particular defined by the first and second direction of extension. This measure also leads to an increase of the effective heat exchange surface of the heat exchanger and thus to an increase of the efficiency of the heat exchanger.

In another preferred embodiment, the at least two woven structures or the at least two woven structure planes, respectively, are arranged at a distance from one another along a third direction of extension, which differs from the first and second direction of extension. This measure improves the flow characteristics of the heat exchanger.

Particularly preferably, the at least two woven structure planes are arranged parallel to one another. This measure also improves the flow characteristics of the heat exchanger.

In a further preferred embodiment, the at least two woven structure planes are embodied to be flat or curved. This measure also improves the flow characteristics of the heat exchanger.

In an advantageous further development, the third direction of extension forms a right angle with the woven structure planes. This allows for the realization of the heat exchanger in the manner of a plate heat exchanger with woven structures, which are quasi “stacked on top of one another” along the third direction of the extension. This provides for a realization of the heat exchanger in flat construction. The pressure loss created in the second fluid when flowing through the heat exchanger can furthermore be kept relatively small.

In an advantageous further development, which is an alternative, the third direction of extension forms an acute or an obtuse angle with the woven structure planes. The effective cross-section for the second fluid can be increased once again in this way.

In another preferred embodiment, at least one woven structure has a W-shaped or S-shaped or U-shaped geometry in a cross-section perpendicular to the first direction of extension of the first fluid lines. This variation ensures a particularly effective reinforcement of the tissue in the selected geometry.

In a further preferred embodiment, the first fluid lines and/or the holding elements comprise a textile material or a textile structure. Particularly preferably, the first fluid lines and/or the holding elements consist of such a textile material or such a textile structure.

In a further advantageous further development, at least a first fluid line has the geometry of an oval in a cross-section perpendicular to its first direction of extension. The pressure loss, which occurs in the first fluid when flowing through the fluid lines, can be lowered by means of such oval-shaped first fluid lines. This applies particularly preferably for all present first fluid lines.

Particularly advantageously, the first fluid lines are arranged in a grid-like manner with at least two grid rows and at least two grid columns in the cross-section perpendicular to their first direction of extension. This measure allows for the second fluid to flow around the fluid lines particularly well and thus for a particularly effective heat exchange with the first fluid.

In another advantageous further development, the first fluid lines of at least two adjacent grid rows of the same grid column and/or of at least two adjacent grid columns of the same grid row are aligned with one another. This variation also allows for the second fluid to flow around the fluid lines particularly well and thus for a particularly effective heat exchange with the first fluid.

Particularly advantageously, the first fluid lines of at least two adjacent grid rows and/or of at least two grid columns are arranged offset to one another. This variation also allows for the second fluid to flow around the fluid lines particularly well and thus for a particularly effective heat exchange with the first fluid.

In a further preferred embodiment, the first fluid lines lead with a first longitudinal end into a common fluid distributor for distributing the first fluid into the first fluid lines. In this variation, the first fluid lines furthermore lead with a second longitudinal end into a common fluid collector for collecting the first fluid after flowing through the first fluid lines. The first fluid can be distributed to a plurality of first fluid lines in an installation space-saving manner in this way and can be collected from said fluid lines again after the flow-through. The provision of additional lines for distributing the first fluid to the first fluid lines or for collecting from the first fluid lines, respectively, can be forgone in the case of this variation.

In a further preferred embodiment, the at least one woven structure is comprised of a first partial woven structure and at least a second partial woven structure, which is formed separately from the first partial woven structure. The first partial woven structure and the at least one second partial structure are thereby arranged at a distance from one another, so that the second fluid can flow through the at least one woven structure space, which is formed between the two partial woven structures. The division of the woven structure into at least two partial woven structures leads to reduced pressure losses in the second fluid.

Particularly advantageously, the warp threads and/or the weft threads can be embodied as flexible wire elements of a metal, preferably of aluminum. Such wire elements can be produced with low production costs. The wire elements can in particular be embodied as molded wire parts.

Further important features and advantages of the invention follow from the subclaims, from the drawings, and from the corresponding figure description by means of the drawings.

It goes without saying that the above-mentioned features and the features, which will be described below, cannot only be used in the respective specified combination, but also in other combinations or alone, without leaving the scope of the present invention.

Preferred exemplary embodiments of the invention are illustrated in the drawings and will be described in more detail in the description below, whereby identical reference numerals refer to identical or similar or functionally identical components.

BRIEF DESCRIPTION OF THE DRAWINGS

In each case schematically:

FIG. 1 shows an example of a heat exchanger according to the invention in a side view.

FIG. 2 shows the heat exchanger of FIG. 1 in a top view.

FIG. 3 shows two adjacent first fluid lines of the heat exchanger as well as the holding elements holding these fluid lines of a holding structure of the heat exchanger, which are embodied as flexible support wires, in a partial view.

FIG. 4 shows the arrangement forming a woven structure of a plurality of first fluid lines and holding elements in a cross-section.

FIGS. 5-10 show different variations of the arrangement shown in FIG. 4.

FIG. 11 shows a further development of the examples of FIGS. 5 to 10, in which the woven structure is comprised of three separate partial woven structures, which are arranged at a distance from one another.

FIG. 1 schematically illustrates an example of a heat exchanger 1 according to the invention in a side view, FIG. 2 in a top view. The heat exchanger 1 comprises a plurality of first fluid lines 2 of a flexible material 13, through which a first fluid F₁ can flow. The first fluid lines 2 are embodied as flexible tubular bodies 8, which define a line interior 9, through which the first fluid F₁ can flow, in a fluid-tight manner. The heat exchanger 1 furthermore comprises a holding structure 3, which has a plurality of holding elements 4 for holding the first fluid lines 2 (for the sake of clarity, the holding structure 3 comprising the holding elements 4 is not included in FIG. 1). The first fluid lines 2 and the holding elements 4 form a plurality of woven structures 5. The first fluid lines 2 thereby form warp threads 6 and the holding elements 4 form weft threads 7 of a respective woven structure 5, or vice versa. The holding elements 4, as well as the first fluid lines 2, can also comprise a flexible material or can consist of such a flexible material. The warp threads 6 and/or the weft threads 7 can be embodied as wire elements of a metal, preferably of aluminum.

The first fluid lines 2 extend along a first direction of extension R₁, which determines a main flow direction of the first fluid F₁, which flows through the first fluid lines 2. The first fluid lines 2 are embodied as flexible tubular body 8, which in each case define a line interior 9, through which the first fluid F₁ can flow, in a fluid-tight manner. Second fluid lines 11, through which the second fluid can flow, are embodied by the spaces 10, which are formed between the first fluid lines 2, so that the first fluid F₁ is fluidically separated from the second fluid F₂ and is thermally coupled thereto. The first fluid lines 2 preferably have a line diameter of less than 2 mm in a cross-section perpendicular to the first direction of extension R₁.

The holding elements 4 of the holding structure 3 are embodied in a thread-like or wire-like manner and extend along a second direction of extension R₂, which runs at right angles to the first direction of extension R₁ of the first fluid lines 2. In the scenario of the example of the figures, the holding elements 4 are embodied as flexible support wires 12. The first fluid lines 2, which are embodied as warp threads 6, can be supported, thus mechanically stabilized and can thus be reinforced to the required extent, by means of the support wires 12, which act as weft threads 7.

For clarification purposes, FIG. 3 shows adjacent first fluid lines 2 and the holding elements 4 of the holding structure 3, which hold these fluid lines 2 and which are embodied as flexible support wires 12, in a partial view. As shown in FIG. 3, the first fluid lines 2 preferably have the geometry of an oval in a cross-section perpendicular to their first direction of extension R₁. The first fluid lines 2 and/or the holding elements 4 preferably comprise a textile material or a textile structure. Particularly preferably, the first fluid lines 2 and/or the holding elements 4 consist of a textile material or of a textile structure.

The heat exchanger 1 is embodied so that a second fluid F₂ can flow through—fluidically separated from the first fluid F₁—along the second direction of extension R₂. Second fluid lines 11, through which the second fluid F₂ can flow, are embodied by means of spaces 10, which are formed between the first fluid lines 2, so that the first fluid F₁ is fluidically separated from the second fluid F₂ by means of the flexible material of the first fluid lines 2, but is still thermally coupled thereto for the heat exchange.

In the top view of FIG. 2, three first fluid lines 2 are illustrated in an exemplary manner, which extend along the first direction of extension R₁ and which are arranged at a distance from one another in the second direction of extension R₂. The woven structure 5 shown in FIG. 2 is arranged in a first woven structure plane 18 a, the orientation of which is determined by the first and second direction of extension R₁, R₂. It can be gathered from FIG. 1 that the heat exchanger 1 has a plurality of such woven structure planes, in the example of FIG. 1 eight woven structure planes 18 a-18 h, comprising respective woven structures 5 of first fluid lines 2 and holding structures 3. The woven structure planes 18 a-18 h are thereby arranged along a third direction of extension R₃, which extends orthogonally to the first as well as to the second direction of extension R₁, R₂ in the example of FIG. 1. The third direction of extension R₃ thus forms a right angle with the woven structure planes 18 a-18 h.

As can be seen in FIGS. 1 and 2, the first fluid lines 2 lead with a first longitudinal end 15 a into a common fluid distributor 16 for distributing the first fluid F₁ into the first fluid lines 2. With a second longitudinal end 15 b, the first fluid lines 2 lead into a common fluid collector 17 for collecting the first fluid F₁ after flowing through the first fluid lines 2.

The eight woven structure planes 18 a-18 h are preferably arranged parallel to one another. Such a scenario is illustrated in FIG. 4 for the clarification of four woven structure planes 18 a-18 d.

FIG. 5 shows a variation of FIG. 4, in which the third direction of extension forms an obtuse angle α₁ with the woven structure planes 18 a-18 d.

FIG. 6 shows a variation of FIG. 4, in which the third direction of extension forms an acute angle α₂ with the woven structure planes 18 a-18 d.

With regard to the arrangement of the woven structures 5, further possible variations are illustrated in the examples of FIGS. 7 to 10. FIGS. 7 to 10 thereby in each case show the heat exchanger 1 with a cross-section perpendicular to the direction of extension R₁.

In the example of FIG. 7, the first fluid lines 2 of two woven structure planes 18 a, 18 b, 18 c, 18 d, which are adjacent along the third direction of extension R3, are in each case arranged offset to one another along the second direction of extension R2. The individual woven structure planes 18 a-18 d are embodied to be flat and are arranged at an equidistant distance from one another in the direction of extension R3.

In the example of FIG. 8, two first fluid lines 2, which are adjacent along the second direction of extension R₂, are in each case arranged offset to one another in the third direction of extension R₃. In another view, the individual woven structure planes 18 a-18 d, which are defined by the first and second direction of extension R₁, R₂, are embodied so as to be curved in an undulated manner.

FIGS. 9 and 10 show variations, in which the woven structure 5 extends alternately along the second direction of extension R₂ and the third direction of extension R₃ in sections in the cross-section perpendicular to the first direction of extension R₁. In the cross-section of FIG. 9, an S-shaped or reversed S-shaped contour of the woven structure 5 results.

Attention shall be drawn below to the illustration of FIG. 10. FIG. 10 illustrates a single woven structure 5 in the cross-section perpendicular to the first direction of extension, which has a W-shaped contour shape. In a further variation, which is not illustrated in the figures, a U-shaped contour is also conceivable instead of a W-shaped contour.

It can be gathered from the illustrations of FIGS. 4 to 8 that the first fluid lines 2 are arranged in a grid-like manner with at least two grid rows 20 and at least two grid columns 19 in the cross-section perpendicular to their first direction of extension R₁.

In the examples of FIGS. 4 to 6, the first fluid lines 2 of all adjacent grid rows 20 of the same grid column 19 are aligned with one another. All adjacent grid columns of the same grid row 20 are also aligned with one another.

In the example of FIG. 7, the first fluid lines 2 of two grid rows 20, which are adjacent in the third direction of extension R₃, are arranged offset to one another along the second direction of extension R₂.

In the example of FIG. 8, the first fluid lines 2 of two grid columns 19, which are adjacent in the second direction of extension R₂, are arranged offset to one another along the third direction of extension R₃.

FIG. 11 illustrates a further development of the examples of FIGS. 5 to 10, in which the woven structure 5 is comprised of three separate partial woven structures 5 a, 5 b, 5 c, which are arranged at a distance from one another. The three partial woven structures 5 a, 5 b, 5 c are arranged at a distance from one another, so that the second fluid F₂ can flow through the woven structure spaces 21 formed between the partial woven structures 5 a, 5 b, 5 c. 

1. A heat exchanger for a motor vehicle, comprising: a plurality of first fluid lines of a flexible material, through which a first fluid (F₁) can flow, and a holding structure having a plurality of holding elements for holding the first fluid lines, wherein the first fluid lines and the holding elements form at least one woven structure, wherein the first fluid lines form warp threads of the at least one woven structure, and the holding elements form the weft threads of the at least one woven structure, or vice versa, wherein the holding elements of the holding structure are in a thread-like manner and extend along a second direction of extension (R₂), which extends at right angles to a first direction of extension (R₁), along which the first fluid lines extend, wherein the heat exchanger, through which a second fluid (F₂) can flow, is fluidically separated from the first fluid (F₁) and along the second direction of extension (R₂), wherein the at least one woven structure includes a first partial woven structure and at least a second partial woven structure, which is formed separately from the first partial woven structure, wherein the first partial woven structure and the at least one second partial structure are arranged at a distance from one another, so that the second fluid (F₂) can flow through the at least one woven structure space, which is formed between the two partial woven structures, and wherein the first and the second partial woven structures are arranged at an angle relative to one another with respect to the second direction of extension (R2).
 2. The heat exchanger according to claim 1, wherein the first fluid lines are flexible tubular bodies, which define a line interior in a fluid-tight manner, through which the first fluid (F₁) can flow, and; the holding elements include a flexible material.
 3. The heat exchanger according to claim 1, further comprising second fluid lines, through which the second fluid (F2) can flow by spaces, which are formed between the first fluid lines, so that the first fluid (F₁) is fluidically separated from the second fluid (F₂) by the flexible material and are thermally coupled thereto.
 4. The heat exchanger according to claim 1, wherein at least one holding element is is a flexible support wire.
 5. The heat exchanger according to claim 1, wherein at least two first fluid lines are arranged at a distance from one another along the second direction of extension (R₂).
 6. The heat exchanger according to claim 1, wherein provision is made for at least two woven structures of first fluid lines and holding elements, which are arranged in a woven structure plane, and defined by the first and second direction of extension (R₁, R₂).
 7. The heat exchanger according to claim 6, wherein the at least two woven structures or at least two woven structure planes are arranged at a distance from one another along a third direction of extension (R₃), which differs from the first and second direction of extension (R₁, R₂).
 8. The heat exchanger according to claim 7, wherein the at least two woven structure planes are arranged parallel to one another.
 9. The heat exchanger according to claim 7, wherein the at least two woven structure planes are flat or curved, at least in sections.
 10. The heat exchanger according to claim 9, wherein the third direction of extension (R₃) forms a right angle with the woven structure planes, or the third direction of extension (R₃) forms an obtuse or acute angle (α₁, α₂) with the woven structure planes.
 11. The heat exchanger according to one of the preceding claims, at least one woven structure has one of a W-shaped, a S-shaped, and a U-shaped geometry in a cross-section perpendicular to the first direction of extension (R₁) of the first fluid lines.
 12. The heat exchanger according to claim 1, wherein at least a first fluid line and at least one holding element includes a textile material or a textile structure.
 13. The heat exchanger according to claim 1, wherein at least a first fluid line has a geometry of an oval in a cross-section perpendicular to a first direction of extension (R₁).
 14. The heat exchanger according to one of claim 1, wherein the first fluid lines are arranged in a grid-like manner with at least two grid rows and at least two grid columns in a cross-section perpendicular to their first direction of extension (R₁).
 15. The heat exchanger according to claim 14, wherein the first fluid lines of the at least two adjacent grid rows of the same grid column and of the at least two adjacent grid columns of the same grid row are aligned with one another.
 16. The heat exchanger according to claim 15, wherein the first fluid lines of the at least two adjacent grid rows and of the at least two grid columns are arranged offset to one another.
 17. The heat exchanger according to claim 1, wherein the first fluid lines lead with a first longitudinal end into a common fluid distributor for distributing the first fluid (F₁) into the first fluid lines, and lead with a second longitudinal end into a common fluid collector for collecting the first fluid (F₁) after flowing through the first fluid lines.
 18. The heat exchanger according to claim 1, wherein the warp threads and/or the weft threads are wire elements of a metal wherein the metal is aluminum.
 19. The heat exchanger according claim 1, wherein the angle between the first and the second partial woven structure with respect to the second direction of extension (R₂) is an acute angle.
 20. A heat exchanger for a motor vehicle, comprising: a plurality of first fluid lines of a flexible material, through which a first fluid (F₁) can flow, and a holding structure having a plurality of curvilinear holding elements for holding the first fluid lines, wherein the first fluid lines and the curvilinear holding elements form at least one woven structure, wherein the first fluid lines form warp threads of the at least one woven structure, and the curvilinear holding elements form the weft threads of the at least one woven structure, or vice versa, wherein the curvilinear holding elements of the holding structure are in a thread-like manner and extend along a second direction of extension (R₂), which extends at right angles to a first direction of extension (R₁), along which the first fluid lines extend, wherein the heat exchanger, through which a second fluid (F₂) can flow, is fluidically separated from the first fluid (F₁) and along the second direction of extension (R₂), wherein the at least one woven structure includes a first partial woven structure and at least a second partial woven structure, which is formed separately from the first partial woven structure, wherein the first partial woven structure and the at least one second partial structure are arranged at a distance from one another, so that the second fluid (F₂) can flow through the at least one woven structure space, which is formed between the two partial woven structures, and wherein the first and the second partial woven structures are arranged at angle relative to one another with respect to the second direction of extension (R2). 